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Solar PV Mounting Structure & Steel Profile Solutions- Utility & Commercial Solar PV Racking Systems

 

Manufacturing precision-formed steel and aluminum mounting components for utility-scale ground mount, commercial rooftop, and carport PV installations. Products include cold-formed C, Z, and U channels, Zinc-Aluminum-Magnesium (ZM) coated profiles, ground screws, and structural connectors built to EN 1090-2, ISO 1461, and AS/NZS 1170 standards. Engineered for 25-year structural design life in C1 through C4 atmospheric corrosive environments.

 

 
 
Product Categories

 

Ground Mounting Systems
• Fixed-Tilt Steel Structures: Hot-dip galvanized C and U channel posts, beams, and purlins for high wind and heavy snow environments.

• Single and Dual Pile Systems: Driven C posts and open-profile rams engineered for fast field installation without concrete foundations.

• Tracker Support Profiles: Precision-punched torque tubes, slewing drive adapter plates, and mounting purlins compatible with single-axis tracking systems.

 

Rooftop & Carport Mounting Systems
• Trapezoidal & Standing Seam Roof Clamps: Non-penetrating aluminum alloy (AL6005-T5) clamps and stainless steel (SUS304) fasteners for metal roof profiles.

• Flat Roof Ballasted Frames: Aerodynamic aluminum and galvanized steel supports with preset tilt angles from 10 degrees to 30 degrees.

• Solar Carport Steel Framing: Heavy-gauge structural columns, main rafters, and integrated water drainage gutters for commercial parking structures.

 

 
 
Foundation & Structural Components

Ground Screws & Helical Piles:

Flanged, continuous-thread steel piles featuring a hot-dip galvanized coating thickness of 85 microns or greater.

Cold-Formed Steel Purlins:

Custom-punched C, Z, and Hat profiles produced in continuous lengths up to 12 meters.

 

 

Technical Specifications

 

Parameter

Steel Components

Aluminum Components

Ground Screws

Material Grade

Q235B, Q355B, S235JR, S355JR, S350GD, S450GD

AL6005-T5, AL6063-T6

Q235B, S235JR Steel Tube

Surface Coating

Hot-Dip Galvanized (45 to 100 um) / ZM Coating (120 to 430 g/sqm)

Anodized (10 to 15 um)

Hot-Dip Galvanized (>= 85 um)

Yield Strength

235 MPa to 450 MPa

>= 225 MPa

>= 235 MPa

Profile Thickness

1.5 mm to 4.0 mm

1.2 mm to 5.0 mm

Wall Thickness: 3.0 mm to 4.0 mm

Hole Punching

Inline CNC slotting and hole patterns (Tolerance +/- 0.5 mm)

Pre-machined slots and holes

Top flange connection holes pre-drilled

Design Standards

AS/NZS 1170, Eurocode 3 (EN 1993), IBC 2021

AS/NZS 1664.1, Eurocode 9

DIN EN ISO 1461

Corrosion Protection

ASTM A123, ISO 1461, GB/T 13912

ISO 7599, ASTM B221

ISO 1461

 

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Material & Coating Options

Pre-Coated Zinc-Aluminum-Magnesium (ZM) Steel
• Coating Mass: ZM120 to ZM430 g/sqm.
• Corrosion Resistance: Cut-edge self-healing property prevents edge rust during outdoor exposure, eliminating post-fabrication hot-dip galvanizing for agricultural, coastal, and high-ammonia environments.

 

Hot-Dip Galvanized (HDG) Carbon Steel
• Coating Thickness: Average 65 to 100 um compliant with ISO 1461 and ASTM A123.
• Application: Full-immersion coating applied after cutting, punching, and welding to protect exposed edges and interior tube surfaces.

 

Anodized Aluminum Alloy (AL6005-T5)
• Anodizing Layer: 10 to 15 um standard thickness (up to 20 um available for marine environments).
• Structural Feature: Optimized strength-to-weight ratio for roof load compliance and ease of manual field assembly.

 

Manufacturing & Processing Capabilities

Cold Roll Forming:

12 automated roll-forming production lines processing C, Z, U, and custom hat sections up to 4.0 mm wall thickness.

Inline Servo Punching:

Synchronized CNC punching stations maintaining +/- 0.5 mm hole-to-hole tolerances across 12-meter profile lengths.

Laser Cutting & Brake Pressing:

High-precision fiber laser cutting and CNC bending for complex base plates, gussets, and mounting brackets.

Robotic Welding:

Automated MIG welding stations delivering consistent weld penetration for ground screw top flanges and structural beam assemblies.

 

Quality Control & Compliance

Mill Test Certificates (MTC):

Supplied with every shipment according to EN 10204 3.1, confirming chemical composition and mechanical properties.

Coating Thickness Verification:

Magnetic gauge measurements recorded per production batch to verify zinc, ZM, or anodizing coverage.

Dimensional Inspection:

Caliper, height gauge, and CMM inspection covering profile dimensions, hole pitch, and cross-section squareness.

Corrosion Testing:

Neutral salt spray testing up to 1,500 hours evaluated under ASTM B117 standards.

 

Application Matrix

 

 

Utility-Scale Ground Power Plants:

High-load driven piles and ZM purlins engineered for various soil types including clay, sand, and rocky terrain (Corrosiveness Class C3 to C5).

 

Commercial and Industrial Roofs:

Non-penetrating clamps and light-weight ballasted frames designed for trapezoidal sheet and standing seam roofs.

 

Solar Carports & Agrivoltaics:

Long-span steel frames and waterproof gutter systems engineered for elevated clearance and multi-use land layouts.

 

 

 

Order Quantities & Lead Times

Minimum Order Quantities (MOQ):
• Standard Roll-Formed Steel Profiles: 10 Metric Tons per size.
• OEM Stamping & Mounting Hardware: 5,000 Pieces.
• Standard Steel Ground Screws: 500 Pieces.

 

Production Lead Times:
• Standard Profiles and Purlins: 15 to 20 days post drawing approval.
• Custom OEM Tooling & Sample Approval: 25 to 30 days.
• Production Capacity: 12,000 Metric Tons per month for structural racking profiles.

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Packaging & Export Logistics

 

Export Bundle Packaging: Profiles secured with heavy-duty steel strapping, corner edge protectors, and timber skids designed for forklift handling.

 

Moisture Protection: Interleaving anti-rust paper and plastic wrapping applied to pre-galvanized and ZM profiles to prevent white rust during ocean transport.

 

Container Loading Optimization: Profile lengths cut to exact container dimensions (5.8 meters for 20GP / 11.8 meters for 40HQ) to maximize payload density and lower freight cost per watt.

 

 

FAQ

 

 

Q: What is the operational difference between Hot-Dip Galvanized (HDG) steel and Zinc-Aluminum-Magnesium (ZM) steel for solar racking?

A: HDG steel components are fabricated first and then immersed in molten zinc, producing a thick coating (65 to 100 um) suitable for highly aggressive environments. ZM steel utilizes pre-coated steel coils containing zinc, aluminum, and magnesium. ZM provides equivalent or superior corrosion protection at thinner coating weights and offers cut-edge self-healing protection, reducing processing steps and overall component cost.

Q: How are hole position tolerances controlled across long purlin profiles?

A: All mounting holes and slots are produced via inline CNC servo-controlled punching units integrated into the roll-forming process. This eliminates cumulative pitch errors and maintains a hole-center tolerance of +/- 0.5 mm across a full 12-meter purlin, ensuring bolt hole alignment during site installation.

Q: Do you provide structural engineering calculations and shop drawings for project sites?

A: Yes. Structural calculation reports and detailed shop drawings can be provided based on project design inputs, including local wind speed, snow load, module specifications, and soil conditions compliant with Eurocode, AS/NZS 1170, or IBC standards.

Q: What measures do you take to prevent white rust (wet storage stain) during sea freight?

A: Pre-galvanized and Zinc-Aluminum-Magnesium (ZM) profiles are treated with anti-corrosion passivation before packaging. During bundling, water-resistant interleaving paper or protective film is placed between layers, accompanied by desiccant bags inside waterproof plastic wrapping. Outer steel strapping and timber skids elevate bundles off container floors, preventing moisture buildup during ocean transit.

Q: How do you guarantee steel grade traceability and consistency for large project orders?

A: Every batch of raw steel coil is sourced from certified tier-1 steel mills with full material traceability. We track melt cast numbers from raw coil reception through roll forming, punching, and hot-dip galvanizing. Complete Mill Test Certificates (MTC) conforming to EN 10204 3.1 are provided per heat number, detailing chemical heat analysis and mechanical test results.

Q: Can you accommodate design modifications or drawing updates after order placement?

A: Minor slot or hole pattern adjustments can be accommodated prior to line setup. For major structural changes involving profile dimensions or thickness, our engineering team conducts a rapid feasibility review within 24 to 48 hours. If modified tooling or new roll-forming dies are required, we update shop drawings and confirm any adjusted lead times or sample approval procedures before proceeding with mass production.

 

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Request a Quote (RFQ)

To assist our engineering team in preparing an accurate quote and structural estimate, please provide:

Site Location & Environmental Data: Maximum wind speed (m/s or mph), snow load (kN/sqm), and distance to coastline.

PV Module Specifications: Module dimensions (Length x Width x Thickness), power rating, and array layout (Portrait or Landscape).

Tilt Angle & Ground Clearance: Required array tilt angle and minimum clearance from ground level.

Foundation Specification: Preferred foundation type (Ground screw, driven pile, or concrete ballast).

Drawing Files: CAD (.dwg / .dxf) or PDF drawings for custom OEM structural profiles.

Contact Engineering & Sales
Email: info@tjrsr.com | Phone / WhatsApp: +86 159 0023 5505
Technical inquiry response time: Within 24 business hours.

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